Pattern mechanism for tufting machines



May 5, 1970 c. w. WATKINS 3,510,039

PATTERN MECHANISM FOR TUFTING MACHINES Filed Feb. 29, 1968 3 Sheets-Sheet 1 INVENTOR. Charles W. Watkins witness BY fl lmJ zai ATTORNEY May 5, 1970 c. w. WATKINS PATTERN MECHANISM FOR TUFTING MACHINES 3 Sheets-Sheet 2 Filed Feb. 29, 1968 INVENTOR. Charles W. WGfkH'IS ATTORNEY y 5, 1910 c. w. WATKINS 3,510,039

PATTERN MECHANISM FOR TUFTING MACHINES Filed Feb. 29, 1968 3 Sheets-Sheet 5 INVENTOR. Charles W. Wafkin ATTORNEY United States Patent 3,510,039 PATTERN MECHANISM FOR TUFTING MACHINES Charles William Watkins, Hixon, TenlL, assigrlor to The Singer Company, New York, N.Y., a corporation of New Jersey Filed Feb. 29, 1968, Ser. No. 709,492 Int. Cl. B24b 51/12 U.S. Cl. 226-409 ABSTRACT OF THE DISCLOSURE This disclosure relates to the textile arts and more particularly to pattern mechanisms for tufting machines. The pattern mechanism disclosed herein includes at least a pair of yarn feed elements disposed for continuous relative driving engagement and selective yarn feeding relationship and each pair of which are relatively movable between a first position for positively feeding at least one yarn end at a speed determined by the speed of the feed elements and a second position wherein the feed of the yarn is substantially uneifected by the pair of yarn feed elements. Means are also disclosed for selectively initiating relative movement of the yarn feed elements between the first and second positions for producing varied patterns in a tufted fabric by varying the pile height, as desired.

Claims SUMMARY OF INVENTION It is a prime purpose of the present invention to provide a pattern mechanism for tufting machines which is capable of producing a plurality of selected pile heights from each yarn strand so that a tufted fabric can be produced having relatively intricate patterns. It is known in the tufting art that variations in the pile height can be brought about, for example, by varying the length of the yarn being fed to the needles during their penetration stroke so that if the length of yarn is decreased on the particular stroke of the needle, the previously formed loop or tuft will be shortened by backrobbing of the yarn from said previously formed loop. Previously known mechanisms of this type generally included mechanisms wherein stationary members were brought into contact with moving or rotating members for varying the rate of the feed of the yarn. As will be apparent, the starting and stopping of such mechanisms during the operation of the machine serves to increase the rate of wear of the components thereof and in some cases effects their efficiency and additionally can put undue strain on the yarn. In the present invention, at least one pair of yarn feed elements, preferably being in the form of feed rolls, is disposed in constant interengaging relationship so that there is no starting and stopping of the elements during operation of the machine and in particular when changes in pattern are called for. Preferably, a plurality of pairs of yarn feed rolls are provided and operating at different speeds with the yarn feed rolls of each pair being rela tively movable into and out of yarn gripping arrangement to feed the yarn at a rate determined by the speed of rotation of the particular pair of yarn feed rolls disposed in yarn gripping relationship. In its boardest sense, one pair of yarn feed rolls may be provided in order to feed the yarn at a rate different from that of the normal rate of feed demanded by the speed of operation of the needles of the machine, so that one pile height is provided by the feed demanded by the needles of the machine and a second pile height is accomplished by actuating the yarn feed rolls into yarn gripping relationship.

In the preferred embodiment illustrated in the drawings, pairs of yarn feed rolls operating at at least two speeds for positively feeding the yarns in a selected manner are provided for producing a tufted fabric having at least two distinct pile heights. A pattern control mechanism is provided through which a desired fabric pattern can be duplicated by generating control signals for actuating the pairs of yarn feed rolls in response to perdetermined control signals. As will be apparent from the detailed description, following below, through the construction of the pattern mechanism of the present invention, the rate of yarn feed that may be selected for each yarn strand can be widely varied so that a wide variation of pile heights can be obtained.

Accordingly, it is one object of the invention to provide a novel and improved pattern mechanism for a tufting machine which is capable of producing varieties of pile heights in a tufted fabric.

It is a further object of the invention to provide a novel and improved yarn mechanism for a tufting machine through which a plurality of rates of yarn feed may be individually selected for yarn strand.

It is an additional object of the invention to provide a novel and improved mechanism for a tufting machine which includes at least one pair of yarn feed rolls disposed in constant driving engagement and which are relatively movable between yarn gripping and non-yarn gripping positions.

Other objects and advantages in the invention will be best understood upon reading the following detailed description of the preferred embodiment of the invention with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partial view of a tufting machine showing the pattern mechanism of the invention supported thereon;

FIG. 2 is a partial view of a tufting machine showing a driving mechanism for the pattern attachment;

FIG. 3 is an enlarged fragmentary view showing a pattern mechanism of the invention;

FIG. 4 is a schematic view showing another embodiment of the invention; and

FIG. 5 is a side view of another embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION Referring to the drawings, particularly FIGS. 1 and 2, there is shown therein a section of the frame 10 of the tufting machine on which is supported the pattern mechanism of the invention. The frame member 10 is intended to be a portion of the standard tufting machine which in themselves are well known in the art and therefore it is not considered necessary to be included in the description hereof since applicant makes no claim to the tufting machine proper itself. The pattern mechanism, which will be described in more detail hereinafter, is further supported on support members 12 and 14 there preferably being a support member 12 and 14 at each side of the machine.

Referring to FIG. 2, a driven shaft 16 which is preferably driven by suitable motor means (not shown) has a sprocket 18 supported thereon which carries a chain 20 which is supported in driving relationship with a sprocket 22 fixedly supported on a rotatable shaft 24. The shaft 24 is connected to a speed reduction unit 26 of a known type which in turn drives a sprocket 28 by suitable well known means. A chain 30 is disposed around the sprocket 28 and engages an idler sprocket 32 for controlling the tension on the chain and at its opposite end from the sprocket 28 is supported on a sprocket 34 supported on and in driving engagement with a shaft 36. As will be described hereinafter, the shaft 36 is supported for driving one of the yarn feed rolls of the pattern mechanism of the invention.

A second drive mechanism is also provided for providing a second portion of the yarn feed attachment as will also be described hereinafter and includes a chain 38 driven by a sprocket (not shown) on the shaft 16 for driving a sprocket 40 fixedly supported on a shaft 42 and connected to a speed reduction unit 44. The speed reduction unit 44 drives a sprocket 46, again in a suitable manner, which in turn carries a chain 48 engaged with an idler 50 and a sprocket 52 driving a shaft 54 which shaft 54 supports a driven yarn feed roll, as will also be described in more detail hereinafter.

Referring to FIG. 3, a preferred embodiment of the pattern mechanism of the invention is shown therein. As previously described shaft 36 is driven and is shown in FIG. 3 as having secured thereto a yarn feed roll 56. The yarn feed roll 56 preferably extends across the entire width of the pattern attachment, although, as will be obvious from the description hereinafter, said yarn feed roll 56 could be made in individual segments. The yarn feed roll 56 preferably comprises a plurality of circumferentially spaced projections or slat members 58 with the slat members 58 being at least coextensive with the circumferentially spaced slat members 60 on the interengaging yarn feed rolls 62, 64, 66 illustrated in the drawings. Although only three yarn feed rolls of the type illustrated as 62, 64, and. 66 are illustrated in the drawings, it should be understood that any number of yarn feed rolls of the type illustrated can be provided, depending of course on the number of needles and yarn ends to be fed. The yarn feed rolls 62, 64, and 66 are freely rotatable about respective stub shafts 68, 70 and 72 and are respectively supported on arm members 74, 76 and 78. The arm members 74, 76 and 78 are in turn supported on actuating members which will be described more completely hereinafter.

In accordance with the invention, the slat members 58 on the yarn feed roll 56 and the slat members 60 on each of the other yarn feed rolls associated with the yarn feed roll 56, are in constant driving or intermeshing engagement so that the pairs of yarn feed rolls comprised of yarn feed rolls 56 and each of the yarn feed rolls 62, 64 and 66 will continuously rotate during operation of the machine. As further illustrated in FIG. 3, particularly with reference to yarn feed roll 62, as an example, it will be seen that each of the slat members 60 has a substantially U-shaped configuration defined by a recess 80 and leg portions 82 on each slat member. The leg portions 82 are of sufficient length to maintain the yarn feed roll 62 in constant meshing engagement with the yarn feed roll 56 even during relative movement of the yarn feed roll 62 toward and away from the yarn feed roll 56, as will be explained hereinafter. Likewise, the recess portions 80 are of sutficient depth to permit a yarn strand, such as that shown at Y, to pass freely between the slats 58 on the yarn feed roll 56 and the slats 60 on the yarn feed roll 62 when said yarn feed rolls are in a position wherein their axes are at the greatest distance from one another during operation of the machine.

In the preferred embodiment illustrated in FIG. 3, a second group of pairs of yarn feed rolls are also provided and are designated with similar numbers as the previously described pairs of yarn feed rolls but with the suflix a aflixed thereto. The operation of the second group of pairs of yarn feed rolls is exactly the same as that heretofore described with the only exception being that the yarn feed roll 56a is driven at a different speed from the yarn feed roll 56 so, as will be explained hereinafter, when the yarn is operatively affected by the yarn feed rolls 56a and 62a, 64a, 66a, the yarn will be fed at a different rate than from the yarn feed roll 56 and its associated yarn feed rolls 62, 64 and 66.

As briefly explained above, each of the yarn feed rolls 62, 64, 66, and 62a, 64a and 66a is supported for relative movement with its associated yarn feed roll 56 and 56a. In the embodiment illustrated in FIG. 3 this relative movement takes the form of moving the first mentioned yarn feed rolls in directions wherein the axis of the first mentioned yarn feed rolls move toward and away from the associated yarn feed rolls 56, and 56a. In order to bring about such relative movement, the arm support member 74 and 74a of the yarn feed rolls 62 and 62a are preferably supported on an elongated arm member 84 for pivotal movement therewith which arm member 84 is in turn pivotally supported intermediate its length on a pivot member 86 which in turn is fixedly carried by the frame member 10 (FIG. 1). The arm member 84 carries at its one end, remote from its connection to a yarn feed roller, a link member 88 pivotally supported to the member 84 and to an actuating rod 90. The actuating rod 90 is reciprocated by a suitable means such as an electromagnetic actuator or a fluid actuator.

In the embodiment shown in FIGS. 1 and 2, a fluid actuator mechanism is provided for causing relative movement between the pairs of yarn feed rolls. As shown in FIGS. 1 and 2 the fluid actuator includes a cylinder 92 having a piston contained therein (not shown), which is connected to the actuator rod 90. Fluid lines 94 and 96 are connected to each end of the cylinder for acting on the face of the piston contained therein with the fluid line 94 being connected to a solenoid valve 98 which regulates the flow of fluid pressure from a manifold 100 and a line 102 to the cylinder 92. The fluid pressure line 96 is in turn connected to a manifold 104. In operation, when fluid pressure from the manifold 100 is connected to cylinder 92 by means of actuation of the solenoid valve 98, fluid pressure will enter the cylinder 92 to cause the actuator rod and its piston to move toward the right and thereby causing the elongated arm member 84 to pivot about its pivot member 86 and disengage the yarn feed rolls 66a and 56a from the yarn feeding position shown in FIG. 1 to a position similar to that shown in the same figure with respect to yarn feed roll 66 and yarn feed roll 56. Such a position is illustrated in FIG. 3. Upon a change in pattern signal, the solenoid valve 98 will move to a different position wherein pressure from the manifold 104, preferably in combination with a spring, will overcome the pressure from the manifold 100 and force the piston to the left as viewed in FIG. 1 to cause the elongated arm member 84 to shift the yarn feed rolls to the position illustrated in FIG. 1 wherein the yarn feed rolls 66a and the yarn feed roll 56a are disposed in yarn gripping arrangement.

The solenoid valve 98 is controlled by a pattern control mechanism such as that diagramatically illustrated in FIG. 4. The pattern control mechanism illustrated in FIG. 4 is preferably of the type disclosed in US. Pat. 3,103,187, issued on Sept. 10, 1963, to W. W. Hammel, In, and in general comprises a pattern drum 106 having a peripheral surface which includes light transmitting and non-transmitting portions in accordance with the pattern desired and a light source (not shown) which is preferably contained within the pattern drum and controlled by a source of power from a light source control box 108, which may also include means for automatically shutting the light off when the machine is not in use. Photocell units 110 are disposed in operative relation with the pattern drum 106 for scanning the pattern on the surface of the drum which photocell units will be individually energized to provide control signals to a relay control center 112 and which in turn provides a proper output signal to an associated solenoid valve 98. Thus, it will be apparent, that the pattern control mechanism will provide predetermined and selected signals to each of the solenoid valves 98 of which there is preferably one for each cylinder 92 associated with an elongated arm 84 as illustrated in FIG. 3. By this means, the yarn feed rolls will be actuated into yarn gripping relationship in accordance with a desired pattern for producing variations in the pile height.

The operation of the embodiments of FIGS. 1-3 will be described in relation to the pairs of yarn feed rolls including rolls 56 and 62 and rolls 56a and 62a for pur" poses of convenience. It will be understood that the operation of each of the other pairs of yarn feed rolls is substantially the same. Upon receiving a predetermined signal from the pattern control mechanism, the elongated arm member 84 will either be shifted to the right or to the left as viewed in FIG. 1. When the elongated arm member is shifted to the right as viewed with reference to FIG. 1, as is the situation shown in FIG. 3, the yarn feed roll 62 of FIG. 3 will be moved toward the yarn feed roll 56 so that the yarn feed Y1 will be disposed in yarn gripping relationship, as illustrated in FIG. 3. In this case the spacing between the recesses 80 in the slats 60 and the slats 58 is not suflicient to permit the yarn to pass freely therebetween but will cause the yarn to be gripped be tween the slats on the two yarn feed rollers and thus the yarn will the fed at a rate determined by the speed of rotation of the yarn feed rollers 56 and 62. At the same time, as viewed in relation to yarn feed rolls 56a and 62a, the spacing between the axis of these two yarn feed rolls will be at their maximum and sufficient space will be provided between the recesses in the slats 60a and the slats 58a to permit the yarn to freely pass therebetween and be substantially unelfected by this pair of yarn feed rolls. When the elongated arm member is shifted to the left as viewed with reference to FIG. 1, the yarn feed rolls 56 and 62 will be moved to a position of maximum distance between their axes wherein the yarn will be substantially unaffected thereby and the yarn feed rolls 56a and 62a will be moved into yarn gripping relationship such that the yarn will now be fed at a rate of speed determined by the speed of rotation of the yarn feed rolls 56a and 62a. It follows that during the tufting operation, because of the change in rate of feed of the yarn and the constant stroke of the needle of the tufting machine, different heights of pile will be provided in a known manner.

Another embodiment of the invention is illustrated in FIG. 4 wherein the operation and structure of the feed rolls themselves is the same as that previously described but the actuation thereof is different. In FIG. 4 it will be seen that the arm supports 78, and 78a, 78a for the yarn feed rolls 66, and 66a are connected directly in a suitable manner to individual electromagnetic actuators, such as solenoids 114 or the like. Each of the electromagnetic actuators 114 is individually connected to the relay control 112 to receive an individual signal from the pattern control mechanism. By this means, individual actuation of each of the pairs of yarn feed rolls can be accomplished in accordance with a desired pattern without causing actuation of any other yarn feed rolls. In other words, in the embodiment of FIG. 4 it does not necessarily follow that because one pair of yarn feed rolls is disengaged from yarn gripping relationship that a second pair must be disposed in yarn gripping relationship, as was the case in the embodiments of FIG. 1 and FIG. 3. Through the construction shown in FIG. 4, any numbers of pairs of yarn feed rolls operating at different speeds can be provided since they are individually actuated and not tied to one another. For example, pairs of yarn feed rolls may be provided which operate at three or four different speeds for feeding three or four different rates of yarn thereby providing a mechanism wherein tufted fabrics may be produced having multiple pile heights such as in the numbers of three, four or more heights of pile. In all other respects however, the concept of operation of the embodiment of FIG. 4 is the same as that illustrated in FIGS. l-3.

In FIG. another embodiment of the invention is illustrated which embodiment is similar in operation to that shown in FIG. 4. In other words in FIG. 5 each of the pairs of yarn feed rolls 56, 66, 56a, 66a and 56b, 66b can be individually and selectively operated. The major difference in the embodiment of FIG. 5 lies in the addition of the pair of the yarn feed rolls 56b, 66b which enables the selective production of one more pile height in the pattern by operating this pair of yarn feed rolls at a dilferent rotation speed than the other two pairs of yam feed rolls. In all other respects the function of the embodiment of FIG. '5 is similar to that described above. As is obvious from the drawing, the yarn feed rolls 66, 66a and 661) are supported on individual pivoted actuating levers 116, 116a and 11612 for relative movement with the yarn feed rolls 56, 56a and 56c. The embodiment of FIG. 5 is otherwise structurally similar to the embodiments illustrated in FIGS. l-4 and like numerals are used to identify like elements.

From the above description, it will be apparent that a novel and improved pattern mechanism for tufting machinery has been provided which is readily adaptable for producing two or more pile heights. The pairs of yarn feed rolls are disposed in constant meshing engagement and are intended to be continuously rotating during operation of the machine so that there is no starting and stop ping of elements during pattern changes. In each of the preferred embodiments, a pattern mechanism is illustrated for producing two pile heights although as explained previously it is possible to provide means for producing more than two pile heights and it is not intended that the invention be limited to the specific embodiments illustrated.

While the invention has been described in detail in its preferred embodiments, it will be understood by those skilled in the art that various modifications and changes may be made therein without departing from the spirit and scope of the invention as described in the appended claims. It is aimed in the appended claims to cover all such modifications.

Having thus set forth the nature of this invention, what I claim herein is:

1. A pattern mechanism for controlling the feed of yarn to a tufting machine including a pair of relatively moveable yarn feed elements disposed for constant relative driving engagement, at least one yarn end disposed between said yarn feed elements, and means for initiating relative movement of said yarn feed elements between a first position wherein said yarn end is fed at a rate determined .by the speed of said yarn feed elements and a second position wherein said yarn feed is substantially unaffected by said yarn feed elements, each of said yarn feed elements being provided with a plurality of spaced projections disposed over its outer surface with the projections on at least one of said yarn feed elements including means for permitting said yarn end to freely pass between said yarn feed elements when said yarn feed elements are in said second position, and each of the projections on one of said yarn feed elements includes a recess therein which permits said yarn end to freely pass between said yarn feed elements when in said second position and said projections coacting with the projections on the other of said yarn feed elements when in said first position to grip said yarn end and feed said yarn end in accordance with the speed of said yarn feed elements.

2. A pattern mechanism as recited in claim 1 wherein said projections comprise slat elements with the slat elements of said yarn feed elements being disposed in meshing relationship such that said yarn feed elements move together.

3. A pattern mechanism as recited in claim 1 wherein said means for initiating relative movement of said yarn feed elements includes an electromagnetic actuator operably connected to at least one of said yarn feed rolls for relatively moving said one yarn feed element between the first and second position.

-4. A pattern mechanism as recited in claim 3 wherein said electromagnetic actuator is disposed in operative relationship with a pattern control mechanism for selectively initiating movement of said yarn feed element in response to predetermined signals from said pattern control mechanism.

5. A pattern mechanism as recited in claim 4 wherein said electromagnetic actuator comprises a solenoid valve, fluid actuator means operably connected to said yarn feed element, and said electromagnetic actuator being operative to control the flow of fluid to said fluid actuator such that said fluid actuator initiates movement of its associated yarn feed element in response to operation of said electromagnetic actuator.

6. A pattern mechanism as recited in claim 1 wherein a plurality of pairs of yarn feed elements are provided with each said pair of yarn feed elements being driven at a difierent speed than each other pair of said yarn feed elements.

7. A pattern mechanism as recited in claim 6 wherein said yarn end is disposed between the yarn feed elements of each of said pairs of yarn feed elements, and said means for initiating relative movement of said yarn feed elements between said first and second positions being responsive to a pattern control means for selectively initiating relative movement of each of said pairs of yarn feed elements.

8. A pattern mechanism as recited in claim 1 wherein a plurality of axially-spaced yarn feed elements are disposed in constant relative driving engagement with at least a second yarn feed element to form a plurality of pairs of yarn feed elements.

Cit

9. A pattern mechanism as recited in claim 8 wherein at least a second plurality of pairs of yarn feed elements is disposed in spaced relationship with said first-mentioned plurality of pairs of yarn feed elements with said second plurality of pairs of yarn feed elements being driven at a difierent speed from said first-mentioned plurality of pairs of yarn feed elements.

10. A pattern mechanism as recited in claim 9 further comprising at least one yarn end disposed between each of said pairs of yarn feed elements with said yarn end further being disposed such that it feeds between one of said first-mentioned pairs of yarn feed elements and one of said second pairs of yarn feed elements and said means for initiating relative movement of said yarn feed elements between said first and second positions being responsive to a pattern control means for selectively initiating relative movement of each of said pairs of yarn feed elements.

References Cited UNITED STATES PATENTS 3,010,632 11/1961 Brautigam 226-190 X 3,116,531 1/1964 Hills et a1 226-176 X 3,119,536 1/1964 Berkeley v n 226-176 X 3,137,429 6/1964 Joslow 226-176 ALLEN N. KNOWLES, Primary Examiner US. Cl. X.R. 226-176, 190 

